Hdpe resins for use in pressure pipe and related applications

ABSTRACT

The present invention provides bimodal polyethylene resins in which the high molecular weight ethylene copolymer component typically has a relatively narrow molecular weight distribution, with short chain branching content being substantially constant across its molecular weight distribution. The resins of this invention are typically characterized by improved toughness and resistance to slow crack propagation properties making them useful for pressure pipe applications.

TECHNICAL FIELD OF THE INVENTION

This invention relates to the field of polyolefin compositions, methodsfor producing polyolefin compositions, articles of manufacture usingpolyolefin compositions, and processes for producing articles ofmanufacture using polyolefin compositions.

BACKGROUND OF THE INVENTION

Polyethylene (PE) is consumed in the USA at the rate of over ten millionmetric tons every year. The semi-crystalline nature of polyethylenemakes it a material of choice for many commodity and specialtyapplications. Crystallinity offers many desirable features to PE such asstiffness, strength, barrier to gas transport, chemical resistance, anddimensional stability. The non-crystalline phase can impart suchattributes as toughness and resistance to slow crack growth.

Presently, a variety of PE resins can be used to produce high stiffnesspipe used in water, gas, and other fluid transport applications.Polyethylene pipe classified as PE-100, MRS 10, or ASTM D3350 typicalcell classification 345566C is especially desirable for use underconditions requiring higher pressure ratings. To obtain a PE-100classification, PE-100 pipe is required to meet certain standardsspecifying stiffness, resistance to slow crack growth, resistance tochemical attack, and low-temperature toughness (expressed as rapid crackpropagation). Further, such pipe must meet a deformation standard whichis determined under pressure at elevated temperatures. Resin which canbe employed to produce both small diameter (1 inch to 12 inches indiameter) and large diameter (greater than 12 inches in diameter) PE-100pipe is described in U.S. Patent Application Pub. No. 2003/0199648 A1(U.S. patent application Ser. No. 10/373,648), published Oct. 23, 2003,which is incorporated herein by reference in its entirety.

It is also desirable for PE-100 pipe to exhibit toughness. Thischaracteristic can be important in many polyethylene pipe applications,such as, where the pipe is buried underground or where the pipe is usedto transport coarse or abrasive slurries. Accordingly, there is a needfor a resin and a PE-100 pipe made therefrom which has improved physicalproperties and impact resistance properties.

SUMMARY OF THE INVENTION

This invention relates to polyolefin compositions, methods for producingpolyolefin compositions, articles of manufacture using polyolefincompositions, and processes for producing pipe and other articles ofmanufacture using polyolefin compositions. More specifically, thisinvention relates to the production of PE-100 classificationpolyethylene pipe and the resin used to make such pipe which haveimproved toughness.

This invention encompasses polyethylene resins, high densitypolyethylene resins, methods of making and using polyethylene resins,articles of manufacture using polyethylene compositions, and processesfor producing articles of manufacture using polyethylene compositions.In the course of examining polymer blends, a high performance polymercomposition was developed that provides a useful combination ofproperties such as polydispersity, short chain branch distribution, longchain branching, rheological properties, and the like, as indicated bymeasures such as Charpy impact toughness and high-stress PENT slow crackgrowth resistance values. For example, the resins of the presentinvention exhibit processing characteristics and properties which aresuitable for, among other uses, pressure pipe applications.

In one aspect, the present invention provides a blend of two differentpolyethylenes such that the blend satisfies some criteria to qualify asPE100 HDPE resins. The component polyethylenes of this invention can betypically produced by using Ziegler-Natta-type or metallocene-typecatalysts using either a Series or a parallel reactor approach. Thepolymer composition comprising a polymer blend can be prepared in anymethod known in the art, including, but not limited to, blending twodifferent ethylene polymers, or making the polymers catalytically usingeither a Series or a parallel reactor approach. Typically, the currentcommercial approach to produce PE100 resins includes blending two broadmolecular weight distribution (MWD) polyethylenes characterized bydiffering molecular weights and short-chain branching (SCB) contents.

In another aspect, this invention provides a polymer compositioncomprising a high molecular weight component comprising an ethylenecopolymer having a substantially uniform short-chain branching (SCB)distribution across its MWD, with a low molecular weight componentcomprising an ethylene homopolymer or copolymer.

Another aspect of this invention is a composition comprising:

a) a high molecular weight component comprising an ethylene copolymercharacterized by a M_(w)/M_(n) less than or equal to about 3.5, asubstantially constant short-chain branching (SCB) profile across themolecular weight distribution, and a number of short-chain branches(SCB) per 1000 backbone carbon atoms from about 4 to about 8; and

b) a low molecular weight component comprising an ethylene homopolymeror copolymer characterized by a M_(w) from about 15 to about 75 kg/mol.

In one aspect, the ethylene homopolymer or copolymer of the low and highmolecular weight components are characterized by low levels ofrheologically significant long branches. Typically, the composition cancomprise from about 45 to about 75 parts by weight high molecular weightcomponent and from about 55 to about 25 parts by weight low molecularweight component. Further, the ethylene copolymer of the high molecularweight component can be further characterized by a M_(w) molecularweight range from about 250 to about 1,000 kg/mol. In another aspect,the number of short-chain branches (SCB) per 1000 backbone carbon atomscan be from about 5 to about 7.

Still another aspect of this invention is a polymer composition whereinthe Razor-Notched Room-Temperature Charpy Energy and the High-StressPENT (standard PENT using a 3.8 MPa initial loading) for the polymerblend compositions indicate exceptional performance. In this aspect, forexample, the composition can be characterized by a room temperatureCharpy impact toughness greater than about 1.5 J, and a density greaterthan or equal to about 0.94 g/cc. In another aspect, the composition canbe characterized by a room temperature Charpy impact toughness greaterthan about 2 J, and a density greater than or equal to about 0.94 g/cc.The polymer blend composition of this invention can also becharacterized by a high-stress PENT slow crack growth resistance valueat a 3.8 MPa initial loading greater than or equal to about 1000 hours,greater than or equal to about 3000 hours, greater than or equal toabout 5000 hours, or greater than or equal to about 6000 hours.

In yet another aspect, this invention provides an article comprising acomposition, wherein the composition comprises:

a) a high molecular weight component comprising an ethylene copolymercharacterized by a M_(w)/M_(n) less than or equal to about 3.5, asubstantially constant short-chain branching (SCB) profile across themolecular weight distribution, and a number of short-chain branches(SCB) per 1000 backbone carbon atoms from about 4 to about 8; and

b) a low molecular weight component comprising an ethylene homopolymeror copolymer characterized by a M_(w) from about 15 to about 75 kg/mol.

In this aspect, the article can be a pipe, a container, a utensil, afilm, a film product, a drum, a fuel tank, a geomembrane, a liner, orthe like. Further, the article can comprise a PE-100 pipe.

This invention further provides a method of making a PE-100 pipecomprising extruding the polymer composition disclosed herein in amolten state through a die to form the PE-100 pipe and cooling the pipe.

In addition, this invention provides a method of making a compositioncomprising combining:

a) from about 45 to about 75 parts by weight high molecular weightcomponent comprising an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, a substantially constantshort-chain branching (SCB) profile across the molecular weightdistribution, and a number of short-chain branches (SCB) per 1000backbone carbon atoms from about 4 to about 8; and

b) from about 55 to about 25 parts by weight low molecular weightcomponent comprising an ethylene homopolymer or copolymer characterizedby a M_(w) from about 15 to about 75 kg/mol.

Further, the present invention provides a process to make a polymer filmcomprising extruding a fluid polymer composition, wherein thecomposition is as disclosed herein.

These and other features, aspects, embodiments, and advantages of thepresent invention will become apparent after a review of the followingdetailed description of the disclosed features.

BRIEF DESCRIPTION OF THE FIGURES

The following is a brief description of the Figures.

FIG. 1 is a graph illustrating the substantially constant short chainbranch distribution across the molecular weight distribution of the CP-1high molecular weight component resin. This resin is used as the highmolecular weight component of the series-2 inventive resins.

FIG. 2 is a comparative graph illustrating the peak location (t_(peak))of the isothermal crystallization exotherms with respect tocrystallization temperature for both inventive and comparative polymerblends.

FIG. 3 is a plot of the peak melting point (T_(m)) plotted as a functionof the crystallization temperature for both inventive and comparativepolymer blends.

FIG. 4 provides a comparative graph of the break stress and strain forboth inventive and comparative polymer blends, with respect tocomposition.

FIG. 5 is a plot of the raw tensile curves for both inventive andcomparative polymer blends of this invention, plotted as load versusextension.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides polyethylene resin compositions, methodsof making and using polyethylene compositions, articles of manufactureusing polyethylene compositions, and processes for producing articles ofmanufacture using polyethylene compositions. Thus, this inventionprovides polymer compositions characterized by a useful combination ofproperties such as polydispersity, short chain branch distribution, longchain branching, rheological properties, and the like, that afford highperformance materials. High performance features can be demonstrated bythe improved toughness and resistance to slow crack propagationproperties of these resins, which illustrates their utility in pressurepipe applications.

In one aspect, the present invention provides bimodal resins comprisinga high molecular weight component and a low molecular weight component.Typically, the high molecular weight component can be characterizedby: 1) a relatively narrow molecular weight distribution; 2) a shortchain branching distribution that is substantially constant over themolecular weight distribution and 3) the absence of substantial amountsof rheologically significant long branches. Typically, the low molecularcomponent comprises low levels of rheologically-significant longbranches. The resins of this invention are typically characterized byimproved toughness and resistance to slow crack growth properties, asmeasured by Charpy impact toughness and high-stress PENT. This inventionalso provides broad molecular weight distribution resins in which shortchain branching (SCB) has been substantially isolated in the highmolecular weight end of the distribution, and short chain branchingdistribution is substantially constant over the high molecular weightend.

The bimodal resins of the present invention, as well as the broadmolecular weight resins in which SCB has been substantially isolated inthe high molecular weight end can be produced by a variety of processes,including, but not limited to, physical mixing blending of componentpolymers, polymerization processes using series or multi-zone reactors,polymerization processes using multi-component catalysts, and the like.Accordingly, the compositions of the present invention are notrestricted according to any one method of preparing the composition.

Components of the Polymer Composition

The present invention provides bimodal resins comprising a highmolecular weight component and a low molecular weight component.Further, this invention also provides broad molecular weightdistribution (MWD) resins in which the features disclosed herein for thehigh molecular weight component of a bimodal resin are found in the highmolecular weight end of the broad MWD. Thus, any properties, features,or characteristics attributed to the high molecular weight component ofa bimodal resin of this invention also describe and can be attributed tothe high molecular weight end of the MWD of any broad molecular weightdistribution resin of this invention.

The molecular weight characteristics of some representative blendcomponents used herein are provided in Table 2. Their SCB content (from1-hexene co-monomer) estimated using NMR is also listed in the sametable. The HP-1 and HP-2 resins are narrow-MWD, high-molecular weighthomopolymers, with the molecular weight of HP-2 being considerablyhigher than that of HP-1. The CP-1 resin is a narrow-MWD, high-molecularweight copolymer with about 5.6 SCB/1000 backbone carbons. The molecularweight and MWD of CP-1 and HP-1 are similar, however they differ intheir SCB content. The LCP-1 and 516-2 resins are low molecular weightblend components, with LCP-1 being a copolymer. The average SCB contentin CP-1 and LCF-1 were verified to be substantially constant acrosstheir entire MWD using a recently-developed sequential SEC-FTIRtechnique (See: P. J. DesLauriers, D. C. Rohlfing and E. T. Hsieh,Polymer, 43, 159 (2002); which is incorporated herein by reference inits entirety.) Thus, the average SCB content in CP-1 and LCP-1 isapproximately constant across their MWD.

High Molecular Weight Component. In one aspect, this invention canprovide a composition comprising:

a) a high molecular weight component comprising an ethylene copolymercharacterized by a M_(w)/M_(n) (polydispersity index or PDI) less thanor equal to about 3.5, a substantially constant short-chain branching(SCB) profile across the molecular weight distribution, and a number ofshort-chain branches (SCB) per 1000 backbone carbon atoms from about 4to about 8; and b) a low molecular weight component comprising anethylene homopolymer or copolymer characterized by a M_(w) from about 15to about 75 kg/mol.

Thus, in this aspect, the high molecular weight component can betypically characterized by: 1) a relatively narrow molecular weightdistribution; 2) a short chain branching distribution that issubstantially constant over the molecular weight distribution; 3) theabsence of rheologically significant long branches. Table 2 providescharacterization data for some representative individual high molecularweight polymer components used to prepare both inventive and comparativepolymer blends of the present invention. High molecular weightcomponents listed in Table 2 are CP-1, HP-1, HP-2, and 516-1.

In another aspect, the high molecular weight component polymers of thisinvention are characterized by having low levels of rheologicallysignificant long branches, meaning that the ratio of the zero shearviscosity (η₀, in Pa-sec) to the weight average molecular weight (M_(w),in kg/mol) is typically less than or equal to about 1,500 Pa-sec/kg/mol.This ratio of η₀ to M_(w) can also be less than about 1,000Pa-sec/kg/mol, and in another aspect, can be less than about 700 Pasec/kg/mol.

In still another aspect of this invention, the high molecular weightcomponent polymers of this invention are characterized by having lowlevels of rheologically significant long branches, meaning that theratio of the zero shear viscosity (η₀ in Pa-sec) to the weight averagemolecular weight (M_(w), in kg/mol) is from about 100 to about 1,500Pa-sec/kg/mol. This ratio of η₀ to M_(w) can also be from about 200 toabout 1,000 Pa-sec/kg/mol, or from about 300 to about 700 Pa-sec/kg/mol.

In another aspect, one feature of the inventive polymers provided in theExamples and the Tables is that, among other things, the high molecularweight component is typically prepared using a metallocene catalyst andits short chain branching distribution is substantially constant acrossits MWD. In comparison, the high molecular weight component of the H516Bresin (516-1) is prepared using a classic Ziegler-Natta catalyst and itsSCB distribution is heterogeneous across its MWD.

The relatively narrow molecular weight distribution of the highmolecular weight component can be seen in its low polydispersity index.Thus, the high molecular weight component of the present invention cancomprise an ethylene copolymer characterized by an M_(w)/M_(n) less thanor equal to about 3.5. In yet another aspect, the high molecular weightcomponent can comprise an ethylene copolymer characterized by anM_(w)/M_(n) less than or equal to about 3.3, or less than or equal toabout 3.1. In comparison, the polydispersity index of 516-1 is measuredto be 4.5.

This invention also provides a high molecular weight componentcomprising an ethylene copolymer characterized by, in one aspect, anM_(z)/M_(w) less than or equal to about 3. In another aspect, theethylene copolymer can be characterized by an M_(z)/M_(w) less than orequal to about 2.7, or an M_(z)/M_(w) less than or equal to about 2.5.

The short chain branching distribution that is substantially constantover the molecular weight distribution, typically, for example, in anM_(w) molecular weight range from about 250 to about 1,000 kg/mol, asdetermined experimentally, is seen in FIG. 1 for the CP-1 high molecularweight component. FIG. 1 indicates that the polymers of the highmolecular weight component of this invention have a flat orsubstantially flat short chain branching profile across its molecularweight distribution. This feature indicates that short chain branchingof the polymers of the present invention remains substantially constantacross the relatively narrow range of molecular weights. In one aspect,the term substantially constant is typically used herein to refer to therange of short-chain branches (SCB) per 1000 backbone carbons can varyover a total range of less than or equal to about 1 SCB/1000C across themolecular weight profile. That is, the variation in the range ofshort-chain branches (SCB) per 1000 backbone carbons can typically varyplus or minus about 0.5 SCB/1000C from the average SCB content acrossits molecular weight profile, for a total range of less than or equal toabout 1 SCB/1000C across the molecular weight profile of the polymer.For the high molecular weight components of the present invention, thevariation in the range of short-chain branches (SCB) per 1000 backbonecarbons can also vary plus or minus about 0.4 SCB/1000C from the averageSCB content across its molecular weight profile, for a total range ofless than or equal to about 0.8 SCB/1000C. In still another aspect, thehigh molecular weight component of the present invention can comprise anethylene copolymer characterized by a number of short-chain branches(SCB) from about 4 to about 8 short-chain branches (SCB) per 1000backbone carbons. Thus, the number of SCB/1000C is a different parameteror measurement than the substantially constant nature of the number ofSCB/1000C. In this aspect, the SCB can also be from about 4.5 to about7.5 SCB/1000C, from about 5 to about 7 SCB/1000C, or about 6 SCB/1000C.

The term high molecular weight component is typically used herein torefer to a polymer characterized by an M_(w) from about 250 kg/mol toabout 1000 kg/mol. In another aspect, the high molecular weightcomponent can be characterized by an M_(w) from about 275 kg/mol toabout 800 kg/mol, or from about 300 kg/mol to about 600 kg/mol.

In another aspect, the high molecular weight component of the presentinvention can comprise an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, and a number of short-chainbranches (SCB) per 1000 backbone carbon atoms from about 4 to about 8across the MWD, in an M_(w) molecular weight range from about 250 toabout 1,000 kg/mol. The ethylene copolymer can also be characterized bya M_(w)/M_(n) less than or equal to about 3.5, and a number ofshort-chain branches (SCB) per 1000 backbone carbon atoms from about 5to about 7 across the MWD, typically, in a M_(w) molecular weight rangefrom about 250 to about 1,000 kg/mol.

The composition of the present invention can comprise from about 45 toabout 75 parts by weight high molecular weight component and from about55 to about 25 parts by weight low molecular weight component, toprovide the desired resin properties. Further, the composition of thepresent invention can also comprise from about 50 to about 60 parts byweight high molecular weight component and from about 50 to about 40parts by weight low molecular weight component.

In another aspect of this invention, the high molecular weight componentcan comprise a copolymer of ethylene and another α-olefin(mono-1-olefin), in which the copolymer can have between about 0.001 andabout 30 weight percent and wherein the mono-1-olefin can have from 3 toabout 12 carbon atoms.

Low Molecular Weight Component. In one aspect, and in addition to thehigh molecular weight component comprising an ethylene copolymerdisclosed herein, the present invention can typically comprise a lowmolecular weight component comprising an ethylene homopolymer orcopolymer, wherein the homopolymer or copolymer can be characterized byan M_(w) from about 15 to about 75 kg/mol. Further, the low molecularweight component ethylene homopolymer or copolymer can be characterizedby an M_(w) from about 25 to about 60 kg/mol, or an M_(w) from about 30to about 50 kg/mol. Table 2 provides characterization data for somerepresentative individual low molecular weight and high molecular weightpolymer components used to prepare the polymer blends of the presentinvention. Low molecular weight components listed in Table 2 are LCP-1and 516-2.

In another aspect, the low molecular weight component polymers of thisinvention are characterized by having low levels of rheologicallysignificant long branches, meaning that the ratio of the zero shearviscosity (η₀, in Pa-sec) to the weight average molecular weight (M_(w),in kg/mol) is typically less than or equal to about 1,500 Pa-sec/kg/mol.This ratio of η₀ to M_(w) can also be less than about 1,000Pa-sec/kg/mol, and in another aspect, can be less than or equal to about700 Pa-sec/kg/mol.

In still another aspect of this invention, the low molecular weightcomponent polymers of this invention are characterized by having lowlevels of rheologically significant long branches, such that the ratioof the zero shear viscosity (η₀, in Pa-sec) to the weight averagemolecular weight (M_(w), in kg/mol) is from about 100 to about 1,500Pa-sec/kg/mol. The ratio of η₀ to M_(w) can also be from about 200 toabout 1,000 Pa-sec/kg/mol, or from about 300 to about 700 Pa-sec/kg/mol.

Preparation of the Polymer Blend Components

The present invention provides a composition comprising a high molecularweight component comprising an ethylene copolymer and a low molecularweight component comprising an ethylene homopolymer or copolymer. Thepolymer blend components can be obtained commercially or can be preparedaccording to any method known to one of ordinary skill in the art. Onemethod of obtaining the individual components of the catalystcomposition is by the catalytic methods employing metallocene-basedcatalyst systems. Examples of some of these methods are provided herein.However, the composition disclosed herein is independent of how theindividual components are prepared or obtained. Further, the compositiondisclosed herein is independent of any method of making the polymerblend components, or any method of making the polymer blend itself.

Comonomers for the High Molecular Weight Component. In one aspect, thehigh molecular weight component of the polymer composition of thisinvention typically comprises a copolymer of ethylene and anotherolefinic compound having from about 3 to about 12 carbon atoms permolecule and having at least one olefinic double bond. Thus, the highmolecular weight copolymer of ethylene typically comprises a majoramount of ethylene (>50 mole percent) and a minor amount of comonomer(<50 mole percent), though this is not a requirement. In another aspect,the comonomers that can be copolymerized with ethylene can have from 3to about 10 carbon atoms per molecule, from 3 to about 8 carbon atomsper molecule, or from about 3 to about 6 carbon atoms per molecule.

In one aspect, acyclic, cyclic, polycyclic, terminal (α), internal,linear, branched, substituted, unsubstituted, functionalized, andnon-functionalized olefins may be employed as comonomers in thisinvention. For example, typical olefins that may be copolymerized withethylene to form the high molecular weight component of this inventioninclude, but are not limited to, propylene, 1-butene, 2-butene,3-methyl-1-butene, isobutylene, 1-pentene, 2-pentene,3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene, 2-hexene, 3-hexene,3-ethyl-1-hexene, 1-heptene, 2-heptene, 3-heptene, the four normaloctenes, the four normal nonenes, the five normal decenes, and mixturesof any two or more thereof. Cyclic and bicyclic olefins, including butnot limited to, cyclopentene, cyclohexene, norbornylene, norbornadiene,and the like, may also be copolymerized with ethylene as disclosedherein.

In one aspect, the amount of comonomer introduced into a reactor zone toproduce the copolymer is generally from about 0.001 to about 30 weightpercent comonomer based on the total weight of the monomer andcomonomer. In another aspect, the amount of comonomer can also be fromabout 0.01 to about 20 weight percent comonomer or from about 0.1 toabout 10 weight percent comonomer based on the total weight of themonomer and comonomer. Alternatively, and in another aspect, an amountof comonomer sufficient to give the above-described concentrations ofcomonomer by weight in the copolymer itself can be used.

In one aspect, the low molecular weight component of the polymercomposition of this invention, like the high molecular weight component,can also comprise a copolymer of ethylene and another olefinic compoundhaving from about 3 to about 12 carbon atoms per molecule and having atleast one olefinic double bond. In this case, the low molecular weightcopolymer of ethylene also typically comprises a major amount ofethylene (>50 mole percent) and a minor amount of comonomer (<50 molepercent), though this is not a requirement. In another aspect, thecomonomers that can be copolymerized with ethylene can have from 3 toabout 12 carbon atoms per molecule, from 3 to about 10 carbon atoms permolecule, from about 3 to about 8 carbon atoms per molecule, or fromabout 3 to about 6 carbon atoms per molecule.

Catalytic Preparation of the Polyolefin Components. The polymercomposition of this invention comprising a polymer blend can be preparedin any method known in the art, including, but not limited to, blendingtwo different ethylene polymers, or making the polymers catalyticallyusing either a Series or a parallel reactor approach. Typically, thecurrent commercial approach to produce PE100 resins includes blendingtwo broad molecular weight distribution (MWD) polyethylenescharacterized by differing molecular weights and short-chain branching(SCB) contents. In one aspect, the high molecular weight ethylenecopolymer and the low molecular weight ethylene homopolymer can beobtained from commercial sources, or can be prepared according tomethods known to one of ordinary skill in the art.

In another aspect, methods by which the polymers of this invention canbe prepared include, but are not limited to, reacting the olefinmonomers with a catalyst comprising the contact product of at least onemetallocene compound, at least one organoaluminum compound, and at leastone chemically-treated solid oxide.

In one aspect, a typical catalyst composition that can be used toprepare the resins of this invention include at least one metallocenecompound, at least one organoaluminum compound, and at least onechemically-treated solid oxide, wherein:

a) the metallocene has the formula:

(X′)(X²)(X³)(X⁴)M′, wherein

-   -   -   M¹ is selected from titanium, zirconium, or hafnium;        -   (X¹) and (X²) are independently selected from a            cyclopentadienyl, an indenyl, a fluorenyl, or a substituted            analog thereof;        -   (X¹) and (X²) are optionally connected by a substituted or            unsubstituted bridging group comprising:        -   i) one atom selected from carbon, silicon, germanium, or            tin, bonded to both (X¹) and (X²); or        -   ii) two or more contiguous carbon atoms in a chain, one end            of which is bonded to (X¹) and the other end of which is            bonded to (X²); and        -   (X³), (X⁴), any substituent on (X¹), any substituent on            (X²), and any substituent on the optional substituted            bridging group are independently selected from an aliphatic            group, an aromatic group, a cyclic group, a combination of            aliphatic and cyclic groups, an oxygen group, a sulfur            group, a nitrogen group, a phosphorus group, an arsenic            group, a carbon group, a silicon group, a germanium group, a            tin group, a lead group, a boron group, an aluminum group,            an inorganic group, an organometallic group, or a            substituted derivative thereof, any one of which having from            1 to about 20 carbon atoms; a halide; or hydrogen;

    -   b) the organoaluminum compound has the formula:

Al(X⁵)_(n)(X⁶)_(3-n),

-   -   -   wherein (X⁵) is a hydrocarbyl having from 1 to about 20            carbon atoms; (X⁶) is selected from alkoxide or aryloxide,            any one of which having from 1 to about 20 carbon atoms,            halide, or hydride; and n is a number from 1 to 3,            inclusive; and

    -   c) the activator-support comprises a solid oxide treated with an        electron-withdrawing anion;        -   wherein the solid oxide is selected from silica, alumina,            silica-alumina, aluminum phosphate, heteropolytungstates,            titania, zirconia, magnesia, boria, zinc oxide, mixed oxides            thereof, or mixtures thereof; and        -   the electron-withdrawing anion is selected from fluoride,            chloride, bromide, phosphate, triflate, bisulfate, sulfate,            or any combination thereof.

Examples of the solid activator-support include, but are not limited to,chlorided alumina, fluorided alumina, sulfated alumina, fluoridedsilica-alumina, a pillared clay, or a combination thereof.

In another aspect of the invention, the organoaluminum compoundcomprises a compound of the formula Al(X⁵)_(n)(X⁶)_(3-n), wherein (X⁵)is a hydrocarbyl having from 1 to about 20 carbon atoms; (X⁶) isselected from alkoxide or aryloxide, any one of which having from 1 toabout 20 carbon atoms, halide, or hydride; and n is a number from 1 to3, inclusive. In another aspect, the organoaluminum compound may beselected from trimethylaluminum, triethylaluminum, tripropylaluminum,diethylaluminumethoxide, tributylaluminum, disobutyl aluminum hydride,triisobutylaluminum, or diethylaluminum chloride. Examples of theorganoaluminum compound include, but are not limited to,triethylaluminum (TEA) or triisobutylaluminum (TIBAL).

Examples of catalyst systems that can be used to prepare the highmolecular weight component of this invention include, but are notlimited to: (η⁵-indenyl)₂HfCl₂, fluorided silica-alumina, andtriisobutylaluminum.

Numerous processes to prepare and use metallocene-based catalyst thatcan be employed in this invention have been reported. For example, U.S.Pat. Nos. 4,939,217, 5,191,132, 5,210,352, 5,347,026, 5,399,636,5,401,817, 5,420,320, 5,436,305, 5,451,649, 5,496,781, 5,498,581,5,541,272, 5,554,795, 5,563,284, 5,565,592, 5,571,880, 5,594,078,5,631,203, 5,631,335, 5,654,454, 5,668,230, 5,705,478, 5,705,579,6,187,880 and 6,509,427 describe such methods, each of which isincorporated by reference herein, in its entirety. Other processes toprepare metallocene compounds that can be employed in this inventionhave been reported in references such as: Köppl, A. Alt, H. G. J. Mol.Catal. A. 2001, 165, 23; Kajigaeshi, S.; Kadowaki, T.; Nishida, A.;Fujisaki, S. The Chemical Society of Japan, 1986, 59, 97; Alt, H. G.;Jung, M.; Kehr, G. J. Organomet. Chem. 1998, 562, 153-181; and Alt, H.G.; Jung, M. J. Organomet. Chem. 1998, 568, 87-112; each of which isincorporated by reference herein, in its entirety. The followingtreatises also describe such methods: Wailes, P. C.; Coutts, R. S. P.;Weigold, H. in Organometallic Chemistry of Titanium, Zironium, andHafnium, Academic; New York, 1974.; Cardin, D. J.; Lappert, M. F.; andRaston, C. L.; Chemistry of Organo-Zirconium and -Hafnium Compounds;Halstead Press; New York, 1986.

Various processes to prepare chemically treated solid oxides (alsotermed activators or activator-supports) that can be employed in thisinvention have also been reported. For example, U.S. Pat. Nos.6,107,230, 6,165,929, 6,294,494, 6,300,271, 6,316,553, 6,355,594,6,376,415, 6,391,816, 6,395,666, 6,524,987, and 6,548,441, describe suchmethods, each of which is incorporated by reference herein, in itsentirety.

Polymerization Processes. Polymerizations to prepare the high molecularweight ethylene copolymer and the low molecular weight homopolymer orcopolymer of this invention can be carried out in any manner known inthe art. Such polymerization processes include, but are not limited toslurry polymerizations, gas phase polymerizations, solutionpolymerizations, and the like, including multi-reactor combinationsthereof. Thus, any polymerization zone known in the art to produceethylene-containing polymers can be utilized. For example, a stirredreactor can be utilized for a batch process, or the reaction can becarried out continuously in a loop reactor or in a continuous stirredreactor.

In one aspect, a typical polymerization method is a slurrypolymerization process (also known as the particle form process), whichis well known in the art and is disclosed, for example in U.S. Pat. No.3,248,179, which is incorporated by reference herein, in its entirety.Other polymerization methods of the present invention for slurryprocesses are those employing a loop reactor of the type disclosed inU.S. Pat. No. 3,248,179, which is also incorporated by reference herein,in its entirety, and those utilized in a plurality of stirred reactorseither in series, parallel, or combinations thereof, wherein thereaction conditions are different in the different reactors.

In another aspect, the polymerizations disclosed herein are carried outtypically using a slurry polymerization process in a loop reaction zone.Suitable diluents used in slurry polymerization are well known in theart and include hydrocarbons that are liquid under reaction conditions.The term “diluent” as used in this disclosure does not necessarily meanan inert material, as this term is meant to include compounds andcompositions that may contribute to the polymerization process. Examplesof hydrocarbons that can be used as diluents include, but are notlimited to, cyclohexane, isobutane, n-butane, propane, n-pentane,isopentane, neopentane, and n-hexane. Typically, isobutane is used asthe diluent in a slurry polymerization. Examples of this polymerizationtechnology are found in U.S. Pat. Nos. 4,424,341; 4,501,885; 4,613,484;4,737,280; and 5,597,892; each of which is incorporated by referenceherein, in its entirety.

For purposes of the invention, the term polymerization reactor includesany polymerization reactor or polymerization reactor system known in theart that is capable of polymerizing olefin monomers to producehomopolymers or copolymers of the present invention. Such reactors cancomprise slurry reactors, gas-phase reactors, solution reactors, or anycombination thereof. Gas phase reactors can comprise fluidized bedreactors or tubular reactors. Slurry reactors can comprise verticalloops or horizontal loops. Solution reactors can comprise stirred tankor autoclave reactors.

Polymerization reactors suitable for the present invention can compriseat least one raw material feed system, at least one feed system forcatalyst or catalyst components, at least one reactor system, at leastone polymer recovery system or any suitable combination thereof.Suitable reactors for the present invention can further comprise anyone, or combination of, a catalyst storage system, an extrusion system,a cooling system, a diluent recycling system, or a control system. Suchreactors can comprise continuous take-off and direct recycling ofcatalyst, diluent, and polymer. In general terms, direct recyclingcomprises the process of recycling a major portion of the liquids backto the reactor without fractionation, after the solids are separatedfrom the liquids in the flash tank. The recycled liquid contains mostlydiluent and unreacted monomers, but can also contain oligomers.Generally, continuous processes can comprise the continuous introductionof a monomer, a catalyst, and a diluent into a polymerization reactorand the continuous removal from this reactor of a suspension comprisingpolymer particles and the diluent.

In one aspect of the invention, the polymerization reactor system cancomprise at least one loop slurry reactor. Such reactors are known inthe art and can comprise vertical or horizontal loops. Such loops cancomprise a single loop or a Series of loops. Multiple loop reactors cancomprise both vertical and horizontal loops. The slurry polymerizationcan be performed in an organic solvent that can disperse the catalystand polymer. Monomer, solvent, catalyst and any comonomer arecontinuously fed to a loop reactor where polymerization occurs.Polymerization can occur at low temperatures and pressures. Reactoreffluent can be flashed to remove the solid resin.

In yet another aspect of this invention, the polymerization reactor cancomprise at least one gas phase reactor. Such systems can employ acontinuous recycle stream containing one or more monomers continuouslycycled through the fluidized bed in the presence of the catalyst underpolymerization conditions. The recycle stream can be withdrawn from thefluidized bed and recycled back into the reactor. Simultaneously,polymer product can be withdrawn from the reactor and new or freshmonomer can be added to replace the polymerized monomer. Such gas phasereactors can comprise a process for multi-step gas-phase polymerizationof olefins, in which olefins are polymerized in the gaseous phase in atleast two independent gas phase polymerization zones while feeding acatalyst-containing polymer formed in a first polymerization zone to asecond polymerization zone.

In still another aspect of the invention, the polymerization reactor cancomprise a tubular reactor. Tubular reactors can make polymers by freeradical initiation, or by employing the catalysts typically used forcoordination polymerization. Tubular reactors can have several zoneswhere fresh monomer, initiators, or catalysts are added. Monomer can beentrained in an inert gaseous stream and introduced at one zone of thereactor. Initiators, catalysts, and/or catalyst components can beentrained in a gaseous stream and introduced at another zone of thereactor. The gas streams are intermixed for polymerization. Heat andpressure can be employed appropriately to obtain optimal polymerizationreaction conditions.

In another aspect of the invention, the polymerization reactor cancomprise a solution polymerization reactor. During solutionpolymerization, the monomer is contacted with the catalyst compositionby suitable stirring or other means. A carrier comprising an inertorganic diluent or excess monomer can be employed. If desired, themonomer can be brought in the vapor phase into contact with thecatalytic reaction product, in the presence or absence of liquidmaterial. The polymerization zone is maintained at temperatures andpressures that will result in the formation of a solution of the polymerin a reaction medium. Agitation can be employed during polymerization toobtain better temperature control and to maintain uniform polymerizationmixtures throughout the polymerization zone. Adequate means are utilizedfor dissipating the exothermic heat of polymerization. Thepolymerization can be effected in a batch manner, or in a continuousmanner. The reactor can comprise a Series of at least one separator thatemploys high pressure and low pressure to separate the desired polymer.

In a further aspect of the invention, the polymerization reactor systemcan comprise the combination of two or more reactors. Production ofpolymers in multiple reactors can include several stages in at least twoseparate polymerization reactors interconnected by a transfer devicemaking it possible to transfer the polymers resulting from the firstpolymerization reactor into the second reactor. The desiredpolymerization conditions in one of the reactors can be different fromthe operating conditions of the other reactors. Alternatively,polymerization in multiple reactors can include the manual transfer ofpolymer from one reactor to subsequent reactors for continuedpolymerization. Such reactors can include any combination including, butnot limited to, multiple loop reactors, multiple gas reactors, multipletubular reactors, a combination of loop and gas reactors, a combinationof autoclave reactors or solution reactors with gas or loop reactors, acombination of tubular and autoclave reactors, multiple solutionreactors, or multiple autoclave reactors, and the like.

After the polymers are produced, they can be formed into variousarticles, including but not limited to, household containers, utensils,film products, drums, fuel tanks, pipes, geomembranes, and liners.Various processes can form these articles. Usually, additives andmodifiers are added to the polymer in order to provide desired effects.By using the invention described herein, articles can likely be producedat a lower cost, while maintaining most or all of the unique propertiesof polymers produced with metallocene catalysts.

Accordingly, one aspect of this invention is a PE-100 pipe comprisingthe composition comprising:

a) a high molecular weight component comprising an ethylene copolymercharacterized by a M_(w)/M_(n) less than or equal to about 3.5, asubstantially constant short-chain branching (SCB) profile across themolecular weight distribution, and a number of short-chain branches(SCB) per 1000 backbone carbon atoms from about 4 to about 8; and

b) from about 55 to about 25 parts by weight low molecular weightcomponent comprising an ethylene homopolymer or copolymer characterizedby a M_(w) from about 15 to about 75 kg/mol.

This invention further encompasses a method of making a PE-100 pipecomprising extruding this composition in a molten state through a die toform and cool the PE-100 pipe. This invention further encompasses amethod of making a composition comprising combining:

a) from about 45 to about 75 parts by weight high molecular weightcomponent comprising an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, a substantially constantshort-chain branching (SCB) profile across the molecular weightdistribution, and a number of short-chain branches (SCB) per 1000backbone carbon atoms from about 4 to about 8; and

b) from about 55 to about 25 parts by weight low molecular weightcomponent comprising an ethylene homopolymer or copolymer characterizedby a M_(w) from about 15 to about 75 kg/mol.

The present invention also encompasses a process to make a polymer filmcomprising extruding an ethylene composition as disclosed herein in afluid state.

Properties of the Polymer Composition

An examination of the Tables, Figures, and Examples disclosed hereinprovides a further description of the resin properties of thisinvention, as follows. To illustrate various aspects of this invention,three sets of two-component blends from various narrow-MWD (molecularweight distribution), linear (low levels of rheologically significantlong branches) polyethylenes were prepared with multiple compositions ineach set of blends. These blends were prepared such that the branching(from 1-hexene co-monomer) was present exclusively on either the high orthe low molecular weight blend component. The average branching contentin each blend component was verified to be approximately constant acrossits. MWD.

The Tables, Figures, and Examples provided herein further illustrate thebi-modal blends based on narrow-MWD components with substantiallyhomogenous distribution of SCB across its MWD. By selectively blendinghomopolymers with copolymers, blends were generated that are similar intheir MWD and average SCB content, but differ in their SCB profile. Dataprovided herein demonstrates how selective SCB placement and the SCBdistribution profile affects bulk crystallization kinetics, tensile andother physical properties of polyethylene (PE).

Table 1 provides some non-limiting examples of preparation conditionsfor the individual component polymers of the present invention,including some non-limiting examples of the catalysts, polymerizationconditions, and resulting resin properties of this invention. Thepolymer composition comprising a polymer blend can be prepared in anymethod known in the art, including, but not limited to, blending twodifferent ethylene polymers, or making the polymers catalytically usingeither a Series or a parallel reactor approach. It is not necessary thatthe polymers presented in Table 1 be produced using the metallocenecatalysts shown in Table 1.

Table 2 illustrates some representative individual polymer componentsused to prepare the polymer blends of the present invention, along withsome typical physical properties of these polymers. Thus, molecularweight data from size-exclusion chromatography (SEC), showing weightaverage molecular weight (MO, the ratio of weight average molecularweight (M_(w)) to number average molecular weight (M_(n)), and the ratioof the z-average molecular weight (M_(Z)) to the weight averagemolecular weight (M_(w)) are provided. Table 2 also provides the numberof short chain branches per 1000 carbon atoms in the polymer backbone asa measure of the short chain branching content in the blend component.Two measures of the molecular weight distribution, M_(w)/M_(n) andM_(z)/M_(w), are also provided in Table 2.

Table 3 illustrates some representative polymer blend compositions ofthe present invention, along with the weight percent of each individualcomponent used to prepare the blend. Polymer blend compositions ofcomparative blends are also provided in Table 3. The polymer blendcompositions labeled as series-2 compositions are the inventivecompositions of this invention. Accordingly, the properties of theseries-2 blends are compared herein to those of the other blends as wellas those of the H516B. The H516B resin is a conventional PE100 pipegrade HDPE produced by Chevron Phillips Chemical Company, which is ablend of two broad MWD, Ziegler-Natta-based polyethylenes. Specifically,H516B is a 54146 blend (weight ratio) of 516-1, the high molecularweight component, and 516-2, the low molecular weight component.

Table 4 provides some of the molecular weight and shear rheologicalcharacteristics of the inventive polymer blends of the present inventionand of the comparative polymer blends, including H516B, for comparisons.

Table 5 illustrates representative physical properties of the inventiveand comparative polymer blends of the present invention, includingH516B, that are pertinent to pressure-pipe applications. As illustratedin Table 5, the Razor-Notched Room-Temperature Charpy Energy and theHigh-Stress PENT (standard PENT at a 3.8 MPa initial loading) for thepolymer blends of the present invention are superior to those of theother blends shown. Further, these performance measures of the polymersof this invention are also superior to those of the H516B resin.

In one aspect, the polymer composition of this invention can becharacterized by an M_(w)/M_(n) less than or equal to about 30, and aMIX less than or equal to about 10. The polymer composition of thisinvention can also be characterized by an M_(w)/M_(n) less than or equalto about 18, and an M_(z)/M_(w) less than or equal to about 5.

In another aspect, the polymer composition of this invention can becharacterized by an M_(w)/M_(n) less than or equal to about 30, lessthan or equal to about 25, less than or equal to about 20, less than orequal to about 15, or less than or equal to about 10. Still anotheraspect is the polymer composition of this invention that can becharacterized by a M_(z)/M_(w) less than or equal to about 10, less thanor equal to about 7, or less than or equal to about 5.

In one aspect, the polymer composition comprising a polymer blend ofthis invention is characterized by having low levels of rheologicallysignificant long branches, meaning that the ratio of the zero shearviscosity (η₀, in Pa-sec) to the weight average molecular weight (M_(w),in kg/mol) is typically less than or equal to about 1,500 Pa-sec/kg/mol.This ratio of η₀ to M_(w) can also be less than about 1,000Pa-sec/kg/mol, and in another aspect, can be less than about 700 Pasec/kg/mol.

In another aspect of this invention, the polymer composition comprisinga polymer blend of this invention is characterized by having low levelsof rheologically significant long branches, meaning that the ratio ofthe zero shear viscosity (η₀, in Pa-sec) to the weight average molecularweight (14, in kg/mol) is from about 100 to about 1,500 Pa-sec/kg/mol.This ratio of η₀ to M_(w) can also be from about 200 to about 1,000Pa-sec/kg/mol, or from about 300 to about 700 Pa-sec/kg/mol.

Another aspect of this invention is the performance features of thecomposition. Thus, the polymer composition can be characterized by aroom temperature Charpy impact toughness greater than about 1.5 J, and adensity greater than or equal to about 0.94 g/cc. The room temperatureCharpy impact toughness can also be greater than about 2 J, and adensity greater than or equal to about 0.94 g/cc. In another aspect, thepolymer composition of this invention can be characterized by ahigh-stress PENT value at a 3.8 MPa initial loading greater than orequal to about 1000 hours. The polymer composition of this invention canalso be characterized by a high-stress PENT value at a 3.8 MPa initialloading greater than or equal to about 3000 hours, greater than or equalto about 5000 hours, or greater than or equal to about 6000 hours.

In yet another aspect, the composition of this invention can becharacterized by a high-stress PENT value at a 3.8 MPa initial loadinggreater than or equal to about 6000 hours and a density greater than orequal to about 0.94 g/cc. The composition can also be characterized by aCharpy impact toughness greater than about 2 J, and a high-stress PENTvalue at a 3.8 MPa initial loading greater than or equal to about 6000hours.

Another feature or aspect of the composition of this invention is apolymer composition characterized by a zero shear viscosity, η₀, lessthan or equal to about 1.5×10⁵ Pa-see. The zero shear viscosity, η₀, canalso be less than or equal to about 1×10⁵ Pa-sec.

The non-isothermal and isothermal melt-crystallization characteristicsof the subject blends were also investigated using Differential ScanningCalorimetry (DSC). The non-isothermal crystallization kinetics of theblends with SCB located on the longer molecules (in the high M_(w)component) displayed a lower sensitivity to thermal history as comparedto those blends with a similar MWD and average SCB content, but with theSCB located on the shorter molecules. The isothermal crystallizationexotherms were observed to shift to longer times and broaden withincreasing crystallization temperature. For a given degree ofundercooling, MWD, average SCB content and total crystallinity, thecrystallization kinetics were substantially slower for thosepolyethylenes with SCB on the longer molecules. Further, the dependenceof the crystallization half time on temperature was substantiallysteeper for those blends with SCB located only on the longer molecules.While not intending to be bound by theory, this observation may suggestthat the slope of the half-time versus temperature plots may be used asa crude indicator of SCB profile in polyethylenes. Also, while notintending to be bound by theory, the crystallization results suggestedthat molecules with SCB behave as though they are much longer; in otherwords, from a crystallization perspective, molecules with SCB are moresluggish compared to perfectly linear molecules of the same length.Therefore, the crystallization process and hence the ultimate morphologyof PE products appears to depend on the SCB distribution profile inaddition to the molecular weight, MWD, and total SCB content.

The instantaneous tensile properties (modulus, yield stress and strain)were also observed to depend on crystallinity and were noted to besubstantially independent of other factors such as molecular weight, MWDand SCB distribution profile. The ultimate tensile properties (breakstress and strain) were also observed to depend strongly on the SCBdistribution profile. The location of SCB along the longer moleculesallows the ability to sustain substantially higher levels of stressprior to breakage; however, the breakage does occur at lower extensions.Thus, in one aspect of this invention, ultimate tensile properties are afunction of the SCB distribution profile, in addition to molecularweight and crystallinity. Further, the onset of tensile strain-hardeningoccurs at significantly lower extensions for those polyethylenes withSCB preferentially located on the longer chains.

To the extent that any definition or usage provided by any documentincorporated herein by reference conflicts with the definition or usageprovided herein, the definition or usage provided herein controls.

The term polymer is used herein to mean homopolymers comprising ethyleneand copolymers of ethylene and another olefinic comonomer, as thecontext requires.

The term low levels of theologically significant long branches is usedherein to indicate that the polymer characterized in this manner meetsat least one of the following criteria. A first criterion of a polymerwith low levels of rheologically significant long branches is that thepolymer typically has a ratio of the zero shear viscosity (η₀, inPa-sec) to the weight average molecular weight (M_(w), in kg/mol) ofless than or equal to about 1,500 Pa-sec/kg/mol. A second criterion of apolymer with low levels of theologically significant long branches isthat the polymer typically has a Carreau-Yasuda (CY) “a” breadthparameter that satisfies the following equation: a≧0.77-0.08(M_(z)/M_(w)). Therefore, the term “low levels ofrheologically significant long branches” can also be used herein toindicate that the polymer is characterized by meeting both these abovecriteria.

The term “across the molecular weight distribution” is generally usedherein to refer to about 90% of the molecules present within the entiremolecular weight distribution of the polymer. The term “entire molecularweight distribution” is defined as the limits across which the sizeexclusion chromatography (SEC) signal (viscosity detector) isdetectable. The term “substantially constant” is generally used hereinto refer to a variation in the range of short-chain branches (SCB) per1000 backbone carbons of plus or minus about 0.5 SCB/1000C from theaverage SCB content across its molecular weight profile. That is, therange of short-chain branches (SCB) per 1000 backbone carbons cantypically vary over a total range of less than or equal to about 1SCB/1000C across the molecular weight profile of the polymer.

Although any methods, devices, and materials similar or equivalent tothose described herein can be used in the practice or testing of theinvention, the typical methods, devices and materials are hereindescribed.

All publications and patents mentioned herein are incorporated herein byreference for the purpose of describing and disclosing, for example, theconstructs and methodologies that are described in the publications,which might be used in connection with the presently describedinvention. The publications discussed above and throughout the text areprovided solely for their disclosure prior to the filing date of thepresent application. Nothing herein is to be construed as an admissionthat the inventors are not entitled to antedate such disclosure byvirtue of prior invention.

For any particular compound disclosed herein, any general structurepresented also encompasses all conformational isomers, regioisomers, andstereoisomers that may arise from a particular set of substituents. Thegeneral structure also encompasses all enantiomers, diastereomers, andother optical isomers whether in enantiomeric or racemic forms, as wellas mixtures of stereoisomers, as the context requires.

EXAMPLES

The present invention is further illustrated by the following examples,which are not to be construed in any way as imposing limitations uponthe scope thereof. On the contrary, it is to be clearly understood thatresort may be had to various other aspects, embodiments, modifications,and equivalents thereof which, after reading the description herein, maysuggest themselves to one of ordinary skill in the art without departingfrom the spirit of the present invention or the scope of the appendedclaims.

General Test Methods

Analysis of the resultant polymers was conducted according to thefollowing procedures. Polymer density was determined in grams per cubiccentimeter (glee) on a compression molded sample, cooled at about 15° C.per hour, and conditioned at room temperature, about 25° C., for about40 hours in accordance with ASTM D1505-68 and ASTM D1928, condition C.

High load melt index (HLMI) was determined in grams of polymer per 10minutes (g/10 min) in accordance with ASTM D1238, Condition 190/21.6, at190° C. with a 21,600 gram weight.

Melt Index (MI) was determined in grams of polymer per ten minutes inaccordance with ASTM D1238, condition 190/2.16, at 190° C. with a 2,160gram weight.

PENT slow crack growth resistance values were obtained at 80° C. (176°F.) according to ASTM F1473 (2001), with the exception that the initialload was 3.8 MPa, in order to accelerate the test. This 3.8 MPa PENTtest may be referred to herein as a “high stress” PENT test.

The Charpy testing was the Razor-Notched Room-Temperature Charpy Energytest carried out according to ASTM F2231.

Molecular weights and molecular weight distributions were obtained usinga PL 220 SEC (Size Exclusion Chromatography) high temperaturechromatography unit (Polymer Laboratories) with trichlorobenzene (TCB)as the solvent, with a flow rate of 1 mL/minute at a temperature ofabout 145° C. BHT (2,6-di-tert-butyl-4-methylphenol) at a concentrationof 0.5 g/L was used as a stabilizer in the TCB. An injection volume of200 μL was used with a nominal polymer concentration of 1.5 mg/mL.Dissolution of the sample in stabilized TCB was carried out by heatingat about 150° C. for about 5 hours with occasional, gentle agitation.Subsequently, the sample was kept at about 130° C. for approximately 18hours (over night) after which it was reheated to about 150° C. forabout 2 hours prior to injection. The columns used were three PLgelMixed A LS columns (7.8×300 mm) and were calibrated with a broad linearpolyethylene standard (Phillips Marlex® BHB 5003) for which themolecular weight had been determined.

Molecular weight distributions with short chain branching profiles wereobtained through size exclusion chromatography using an FTIR detector.Chromatographic conditions are those described above, and the sampleinjection volume was 500 μL. Samples were introduced to the FTIRdetector via a heated transfer line and flow cell (K r windows, 1 mmoptical path, and Ca. 70 uL cell volume). The temperatures of thetransfer line and flow cell were kept at 143±1° C. and 140±1° C.,respectively. Perkin Elmer FTIR spectrophotometer (PE 2000) equippedwith a narrow band mercury cadmium telluride (MCT) detector was used inthese studies. Further details of the procedure can be found in Polymer2002:43:159, by DesLauriers, Rohlfing, D. C., and Hsieh, E. T.

Melt rheology measurements were obtained as follows. Pellet samples werecompression molded at 182° C. for a total of three minutes. The sampleswere allowed to melt at a relatively low pressure for one minute andthen subjected to a high molding pressure for an additional two minutes.The molded samples were then quenched in a cold (room temperature)press. 2 mm×25.4 mm diameter disks were stamped out of the molded slabsfor rheological characterization.

Small-strain (10%) oscillatory shear measurements were performed on aRheometrics Scientific, Inc. ARES rheometer using parallel-plategeometry at a temperature of 190° C. The test chamber of the rheometerwas blanketed with nitrogen in order to minimize polymer degradation.The rheometer was preheated to the test temperature of the study. Uponsample loading and after oven thermal equilibration, the specimens weresqueezed between the plates to a 1.6 mm thickness and the excess wastrimmed. A total of 8.0 minutes elapsed between the time the sample wasinserted between the plates and the time the frequency sweep (0.03-100rad/s) was started. The complex viscosity (n*) versus frequency (ω) datawere then curve fitted using the modified three parameter Carreau-Yasuda(CY) empirical model to obtain the CY parameters viz. zero shearviscosity—η₀, characteristic relaxation time—t_(τ) _(η) and breadthparameter α.

The simplified Carreau-Yasuda (CY) empirical model is as follows.

${{{\eta^{*}(\omega)}} = \frac{\eta_{0}}{\left\lbrack {1 + \left( {\tau_{\eta}\omega} \right)^{a}} \right\rbrack^{{({1 - n})}/a}}},$

wherein: |η*(ω)|=magnitude of complex shear viscosity;

-   -   η₀=zero shear viscosity    -   τ_(η)=viscous relaxation time    -   α=“breadth” parameter

n=fixes the final power law slope, fixed at 2/11; and

ω=angular frequency of oscillatory shearing deformation.

Details of the significance and interpretation of the CY model andderived parameters may be found in: C. A. Hieber and H. H. Chiang,Rheol. Acta, 28, 321 (1989); C. A. Hieber and H. H. Chiang, Polym. Eng.Sci., 32, 931 (1992); and R. B. Bird, R. C. Armstrong and O. Hasseger,Dynamics of Polymeric Liquids, Volume 1, Fluid Mechanics, 2nd Edition,John Wiley & Sons (1987); each of which is incorporated herein byreference in its entirety.

All DSC experiments were performed using a Perkin Elmer Diamond DSCinstrument, that was calibrated using zinc and indium standards for allthe runs. The sample and reference pans were blanketed with nitrogenduring the measurements.

The non-isothermal crystallization data was analyzed using variousempirical equations including the Nadkarni model. See: V. M. Nadkarni,N. N. Bulakh and J. P. Jog, Advances in Polymer Technology, 12, 73(1993); which is incorporated herein by reference in its entirety. Thisapproach provided a procedure for deriving quantitative parameters tocharacterize the crystallizability of the polymers and their sensitivityto processing conditions, mainly cooling rates. Non-isothermalcrystallization data was analyzed in terms of the degree of undercoolingΔT_(c) defined as the temperature difference between T_(m) in thesubsequent heating scan and the temperature at the onset ofcrystallization, T_(b). The variation of ΔT_(c) with cooling rate, x, isfitted to the following equation:

ΔT _(c) =P·λ+ΔT _(c) ⁰

where, ΔT_(c) ⁰ is the degree of undercooling required in the limit ofzero cooling rate and is related to the thermodynamic driving force fornucleation, and the slope, P is a process sensitivity factor thataccounts for the kinetic effects.

Sources of Individual Resin Components

General sources and properties of the individual component resins ofthis invention are as follows. Melt index, molecular weight, and shortchain branching (SCB) properties of this copolymer are provided in Table2. The low molecular weight ethylene homopolymer, designated herein asthe 516-2 resin, was prepared at the Chevron Phillips Pasadena PlasticsComplex, using conventional Ziegler-Natta catalysts and methods to forma polymer having the properties as provided in Table 2, for example,using the Lynx®-100 catalyst system from Engelhard, along with atriethylaluminum (TEA) as the cocatalyst, and H₂ for molecular weightcontrol. The fluff density of the 516-2 resin is maintained to greaterthan or equal to about 0.965 g/cc, and a MI range from about 80 to about120 dg/min, typically around 90 dg/min.

Melt index, molecular weight, and short chain branching (SCB) propertiesof this homopolymer are also provided in Table 2.

The H516B resin used as a comparative example in the Tables and Examplesherein is a conventional PE100 pipe grade HDPE produced by ChevronPhillips Chemical Company, which is a blend of two broad MWD,Ziegler-Natta-based polyethylenes. H516B is a 54/46 (weight ratio) blendof a high molecular weight component designated 516-1, and a lowmolecular weight component, designated 516-2.

The high molecular weight individual component resins of this invention,designated herein as “CP1”, “HP1”, and “HP2”, were prepared according tothe Examples herein. The fluorided silica-alumina activator-support thatwas used to prepare the high molecular weight resins of this inventionis disclosed in WO 9960033, which is incorporated by reference in itsentirety.

Example 1 Preparation of Representative Polymer Components

All polymerization runs were conducted in a one-gallon (3.785 liter)stainless steel reactor. Table 1 provides some representative examplesof preparative conditions for the individual component polymers, bothhigh molecular weight and low molecular weight, of the presentinvention, including some non-limiting examples of the catalysts,polymerization conditions, and resulting resin properties of thisinvention.

Two liters of isobutane and alkyl aluminum were used in all thepreparations shown in Table 2. The olefin comonomer used to prepare thecopolymers, if used, was 1-hexene. The metallocene solution (1 mg/mL)was usually prepared by dissolving 20 mg of metallocene in a mixture of5 mL of hexene, 5 mL of 15 wt % of TEA and 10 mL of toluene.

A typical polymerization procedure is as follows. The alkyl aluminum,chemically-treated solid oxide, and the metallocene solution were addedin that order through a charge port while venting isobutane vapor. Thecharge port was closed and 2 liters of isobutane were added along with1-hexene (if comonomer was used). The contents of the reactor werestirred and heated to the desired run temperature, and ethylene was thenintroduced. Ethylene was fed on demand to maintain the specifiedpressure for the specified length of the polymerization run, as shown inTable 1. The reactor was maintained at the desired run temperaturethrough the run by an automated heating-cooling system.

TABLE 1 Representative preparative methods for some individual componentpolymers of the present invention.^(†) 1- Catalyst Solid Time Temp.Pressure Hexene wt. PE MI HLMI Component Metallocene* (min) (C) (psi)wt. (g) (mg) (g) dg/10 min dg/10 min CP-1 A 30 90 550 50 1 464 0 0.31HP-1 A 90 95 450 0 1 296 0 0.32 HP-2 A 90 90 550 0 1 464 0 0.04 LCP-1 B35 90 550 25 1 548 130.5 — ^(†)In all examples, reactions were conductedusing 200 mg of fluorided silica-alumina activator-support(chemically-treated solid oxide), and 1 mL of 1 M triisobutyl aluminum(TIBA) cocatalyst. *A = (η⁵-indenyl)₂HfCl₂; B = Me₂Si(3-PrCp)₂ZrCl₂.

Example 2 Molecular Weight, Physical Properties, and BranchingProperties of Representative High Molecular Weight and Low MolecularWeight Polymer Components

Table 2 illustrates some representative individual polymer componentsused to prepare the polymer blends of the present invention, along withsome typical physical properties of these polymers. Thus, molecularweight data, obtained as provided in the Examples, showing weightaverage molecular weight (M_(w)), the ratio of weight average molecularweight (M_(w)) to number average molecular weight (M_(a)), and the ratioof the z-average molecular weight (M_(Z)) to the weight averagemolecular weight (M_(w)) are provided.

Table 2 also provides the number of short chain branches per 1000 carbonatoms in the polymer backbone as a measure of the short chain branchinglevel in the polymer. One measure of the molecular weight distribution,M_(w)/M_(n), is also provided in Table 2. Table 2 illustrates that theSCB was restricted to either the high molecular weight component for theinventive resin compositions, or to the low molecular weight componentfor the comparative resin compositions.

TABLE 2 Representative individual polymer components used to prepare thepolymer blends of the present invention. HLMI or SCB/1000 Component MIM_(w) Backbone ID (dg/min) (kg/mol) M_(w)/M_(n) M_(z)/M_(w) Carbons HighMolecular Weight Component CP-1 0.31 369 2.9 2.1 5.6 516-1^(§) 0.55 4464.5 3.4 3.2 HP-1 0.32 398 2.9 2.1 0.0 HP-2 0.05 550 2.5 2.0 0.0 LowMolecular Weight Components LCP-1 130 (MI) 34 2.0 1.6 4.7 516-2^(†)  90(MI) 45 5.3 5.4 0.0 ^(§)516-1 is the high molecular weight component ofH516B. ^(†)516-2 is the low molecular weight component of H516B and ofthe series-2 inventive resins.

Example 3 Representative Polymer Blend Compositions

Representative polymer blends of the present invention, both inventiveand comparative, are illustrated in Table 3. The inventive compositionsof this invention are the polymer blend compositions labeled asseries-2. Accordingly, the properties of the series-2 blends arecompared herein to those of the other blends as well as those of theH516B. The H516B resin is a conventional PE100 pipe grade HDPE producedby Chevron Phillips Chemical Company, which is a blend of two broad MWD,Ziegler-Natty-based polyethylenes.

The high molecular weight components (HP-1, HP-2, and CP-1) were blendedwith the low molecular weight components (LCP-1 and 516-2) to create aseries of blends that allow the influence exerted by the targetedplacement of SCB in the ultimate blend to be examined. These blends aredescribed in Table 3, and are labeled as series-1, series-2 andseries-3. The comparative polymer blends are the series-1 and series-3blends and these blends contain SCB only along the low end of the MWD,with series-3 being a relatively higher molecular weight collection ofblends. While the molecular weight characteristics of the inventiveseries-2 blends were verified to be similar to their series-1counterparts, the SCB was placed along the longer molecules in series-2blends.

TABLE 3 Representative polymer blend compositions of the presentinvention and compositions of comparative polymer blends. BLEND No.COMPONENTS A/B WEIGHT RATIO A/B series-1: Comparative BM1-1 HP-1/LCP-152/48 BM1-2 HP-1/LCP-1 60/40 BM1-3 HP-1/LCP-1 68/32 series-2: InventiveBM2-1 CP-1/516-2 52/48 BM2-2 CP-1/516-2 60/40 BM2-3 CP-1/516-2 68/32series-3: Comparative BM3-1 HP-2/LCP-1 52/48 BM3-2 HP-2/LCP-1 60/40

Example 4 Molecular Weight and Rheological Characteristics ofRepresentative Inventive and Comparative Polymer Blends of the PresentInvention

As illustrated in Table 4, molecular weight and shear rheologicalcharacteristics of the inventive polymer blends of the present inventionand of the comparative polymer blends, including H516B, were measuredand are provided.

TABLE 4 Molecular weight and shear rheological characteristics of theinventive polymer blends of the present invention and of the comparativepolymer blends, including H516B. M_(w) η₀ τ_(η) Sample ID (kg/mol)M_(w)/M_(n) M_(z)/M_(w) (Pa · s) (s) a series-1: Comparative BM1-1 2306.7 3.8 50200 0.4 0.57 BM1-2 245 6.6 3.1 89100 0.5 0.57 BM1-3 265 6.12.8 321000 1.3 0.39 series-2: Inventive BM2-1 242 15.7 3.6 64900 0.40.54 BM2-2 242 12.4 3.6 98800 0.5 0.56 BM2-3 276 11.1 2.9 318000 1.210.41 series-3: Comparative BM3-1 276 11.9 4.4 151000 1.1 0.60 BM3-2 3458.8 3.2 241000 1.3 0.62 Comparative H516B 280 18.0 5.8 192000 1.3 0.35

Example 5 Density, RT Charpy, and PENT Properties of RepresentativeInventive and Comparative Polymer Blends of the Present Invention

As illustrated in Table 5, the polymer compositions of this inventionprovided a useful combination of polyolefin properties such aspolydispersity, long chain branching, rheological properties, and thelike, that afford high performance materials, as indicated by measuressuch as Charpy impact toughness and high-stress PENT slow crack growthresistance values. These properties made these resins suitable for,among other uses, pressure pipe applications.

As seen in Table 5, the Razor-Notched Room-Temperature Charpy Energy andthe High-Stress PENT (standard PENT at a 3.8 MPa initial loading) forthe polymer blends of the present invention are superior to those of theother blends shown. Further, these performance measures of the polymersof this invention are also superior to those of the H516B resin.

TABLE 5 Representative physical properties of the inventive andcomparative polymer blends of the present invention, including H516B,that are pertinent to pressure-pipe applications. Density RT Charpy PENTResin/Blend ID (g/cc) (J) (hrs; @ 3.8 MPa) Inventive Polymer BlendsBM2-1 0.9502 2.31 >6000 BM2-2 0.9445 2.44 >6000 BM2-3 0.940 2.64 >6000Comparative Polymer Blends BM1-1 0.9507 0.31 0.05 BM1-2 0.9502 1.54 0.30BM1-3 0.9490 2.19 0.65 BM3-1 0.9485 0.68 0.45 BM3-2 0.9470 2.55 1.10H516B 0.9605 0.60-2.20 300-600 (with carbon black)

Example 6 Non-Isothermal Melt Crystallization Characteristics ofRepresentative Inventive and Comparative Polymer Blends of the PresentInvention

The non-isothermal melt crystallization characteristics of the subjectblends were examined by cooling the blends from 170° C. to 0° C. atvarious rates in a DSC instrument. The location of the crystallizationexotherm shifted to lower temperatures at higher cooling rates, due tokinetic effects. The slope of the exotherm peak location versus coolingrate averages −0.27 for the series-1 and series-3 blends. However, thesame slope for series-2 blends is −0.21. While not intending to be boundby theory, this observation suggested that the non-isothermalmelt-crystallization kinetics were influenced by the SCB distributionprofile, with the crystallization rate being less sensitive to thecooling rate for those blends with SCB located along the longermolecules. The melting characteristics of the above non-isothermallycrystallized specimens were characterized as well. The peak meltingpoint (T_(m)) of the non-isothermally crystallized specimens decreasedwith increasing cooling rate. At high cooling rates (largeundercoolings), relatively less-perfect crystals were formed thateventually melted at lower temperatures. For a given cooling history,T_(m) decreased with increasing molecular weight. Further, for a giventhermal history, MWD, and average SCB content, the T_(m) was lower forthose polymers in which the SCB was located on the longer molecules.Again, while not intending to be bound by theory, these T_(m) resultswere attributed to trends in lamellar thickness.

Non-isothermal crystallization data was also analyzed in terms of thedegree of undercooling ΔT_(c) defined as the temperature differencebetween T_(m) in the subsequent heating scan and the temperature at theonset of crystallization, T_(b). The variation of ΔT_(c) with coolingrate, x, was fitted to the following equation:

ΔT _(c) =P·χ+ΔT _(c) ⁰

where, Δ_(c) ⁰ is the degree of undercooling required in the limit ofzero cooling rate and is related to the thermodynamic driving force fornucleation, and the slope, P is a process sensitivity factor thataccounts for the kinetic effects. Thus, ΔT_(c) ⁰ for all the blends wasobserved to be within a 3° C. window. The parameter P was observed to besmaller for series-2 blends relative to series-1 and series-3 blends.While not bound by theory, this observation appears to confirm theresults that indicate a lesser sensitivity to process history for thosepolymers with SCB present along the longer molecules.

Example 7 Isothermal Crystallization Characteristics of RepresentativeInventive and Comparative Polymer Blends of the Present Invention

The isothermal crystallization characteristics of these blends were alsoinvestigated. The crystallization exotherms, in general, became broaderand its location shifted to longer times at higher temperatures.Further, the enthalpy of crystallization also decreased slightly withincreasing temperature. The peak location (t_(peak)) of the isothermalcrystallization exotherms is plotted as a function of crystallizationtemperature for all the blends in FIG. 2. As can be seen, t_(peak)increased exponentially with increasing temperature for all the blends;however, this dependence (slope) was much greater for inventive series-2blends. In general, this slope increased with increasing molecularweight for each blend series indicating slower crystallization kineticsfor longer molecules. Further, it was clear that this slope wassignificantly larger for the series-2 blends. For instance, despite thesimilar molecular weight, MWD, shear rheology and average SCB contentfor blends BM1-1 and BM2-1, the crystallization kinetics of BM2-1 weresubstantially slower. While not intending to be bound by theory, it islikely that the placement of SCB on the longer molecules makes them moresluggish from a crystallization perspective.

The above isothermally crystallized specimens were subsequently heatedfrom the isothermal crystallization temperature to capture the meltingtransition. FIG. 2 shows the peak melting point (T_(m)) plotted as afunction of the crystallization temperature for all the blends. Asystematic increase in T_(m) with increasing crystallization temperatureis clearly evident in FIG. 2. While not intending to be bound by theory,it is likely that, thicker and more perfect lamellar crystals formed athigher temperatures (lower undercooling), which translated to higherobserved melting points. For a given thermal history, T_(m) for series-2blends was consistently lower than that of either series-1 or series-3blends, even though these blends were fairly matched in terms of theirMWD and average SCB content.

Further, for the comparative series-1 and series-3 blends, T_(m)increased with increasing molecular weight. As T_(m) is primarily afunction of the average thickness of the lamellar crystals present, andagain while not intending to be bound by theory, the increasing T_(m)with molecular weight for series-1 and series-3 blends can be explainedin terms of fewer interruptions during the crystallization process oflong, linear molecules. Series-2 blends, however, with SCB along thelongest molecules, likely experience many interruptions during thecrystallization process. While again not intending to be bound bytheory, it is thought that these SCB that have to be excluded from thecrystal lattice interrupt the crystal thickening process, thus loweringthe average lamellar thickness. Possibly, this interruption is alsolikely responsible for the slower crystallization kinetics of moleculeswith SCB.

Example 8 Tensile Properties of Representative Inventive and ComparativePolymer Blends of the Present Invention

The tensile properties of the subject blends were investigated usingcompression-molded plaques from which dog-bone specimens were stampedout. The instantaneous tensile properties, namely modulus, yield stressand yield strain were found to be dependent almost entirely on densityor crystallinity. The ultimate properties (break stress and strain) areknown to depend on both crystallinity and molecular weight. Demonstratedhere is the influence exerted by SCB distribution on the ultimatetensile properties of PE. FIG. 4 shows the break stress and strain forthe blends plotted as a function of composition. The break stressincreases somewhat with molecular weight initially; however, at thehighest molecular weight in each series, the break stress decreasessomewhat. While not intending to be bound by theory, this maxima in thebreak stress versus blend composition may be attributed to competingeffects between molecular weight and crystallinity. An interestingfeature to note is that the break stress for series-2 blends isconsistently and substantially higher than that of series-1 and series-3blends despite the similarities in the MWD and average SCB content. Itis also important to note that the break stress for series-2 blends issubstantially higher even though they are, on average, less crystallinecompared to their counterparts in the other two blend sets. While thebreak stress for series-2 blends is high, their break strain isconsistently and considerably lower than that of the other blends.Therefore, the ultimate tensile properties are found to depend stronglyon the SCB distribution profile. The location of SCB along the longermolecules slows the crystallization kinetics and consequently increasesthe tie-molecule concentration sufficiently such that thesemi-crystalline structure allows the ability to sustain substantiallyhigher levels of stress prior to breakage. In other words, placing a fewSCB on the longest molecules of a PE produces the tensile traits of asignificantly higher molecular weight polymer, all else being equal.Further, despite the crystallinity and molecular weight differencesbetween the three blend series, SCB distribution appears to exert thestrongest influence on the ultimate tensile properties of PE.

FIG. 5 shows the raw tensile curves, plotted as load versus extension.Following the linear elastic region at low strain, a peak in the load isevident in the vicinity of the yield point. The load drops after theyield and a plateau in the load follows. During this plateau, thematerial is likely undergoing post-yield non-recoverable deformationsthat involves destruction and re-formation of the lamellar crystals. Atsufficiently high strains, a distinct increase in the slope of theload-displacement curve is clearly evident. This increase in slope isusually associated with the onset of “strain-hardening”. The extensionat which strain-hardening begins to occur is noted to depend distinctlyon the SCB distribution across the MWD of the polymer. Specifically, theonset of strain-hardening occurs at significantly lower extensions forthose polyethylenes with SCB located on the longer chains. Further, theonset of strain-hardening is also noted to occur at slightly lowerextensions with increasing molecular weight. Thus, the ability ofseries-2 blends to sustain higher loads prior to failure is noted to bea consequence of the earlier onset of strain-hardening. While this onsetof strain-hardening, also referred to as the natural draw-ratio, hasbeen reported to influence the load-bearing capability of polymericproducts, one aspect of this invention is the relationship between thestrain-hardening character of PE and molecular architecture.

Example 9 Ductile-Brittle Transition Temperature (T_(db)) Measurementsof Resins

The razor-notched Charpy impact energy measured at room-temperatureprovides a good measurement of the inherent fracture toughness of apolymer. The same Charpy test (ASTM F2231) was performed at multipletemperatures, because when the temperature is sufficiently low, thespecimen failure mode will change from “ductile” to “brittle”. Thetemperature at which this failure mode change occurs is referred to asthe ductile-brittle transition temperature (T_(db)). The T_(db) isanother physical property relevant for pressure pipe applications, wherelower T_(db) is desirable. Table 6 illustrates the T_(db) data for theinventive and comparative compositions.

TABLE 6 Ductile-brittle transition temperature (T_(db)) measurements ofinventive and comparative polymer blends. BLEND No. T_(db) (° C.)Inventive Blend BM2-1 <−30 Comparative Blend BM1-1 −18 H516B −29

1-32. (canceled)
 33. A method of making a composition comprising a highmolecular weight component and a low molecular weight component, themethod comprising: (i) blending the high molecular weight component andthe low molecular weight component to form the composition; or (ii)producing the high molecular weight component and the low molecularweight component in a multiple polymerization reactor system comprisingat least two polymerization reactors configured in series or inparallel, and combining the high molecular weight component and the lowmolecular weight component in the reactor system to form thecomposition; or (iii) both (i) and (ii); wherein: a) the high molecularweight component comprises an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, a substantially constantshort-chain branching (SCB) profile across the molecular weightdistribution, and a number of short-chain branches (SCB) per 1000backbone carbon atoms from about 4 to about 8; and b) the low molecularweight component comprises an ethylene homopolymer characterized by aM_(w) from 25 to 60 kg/mol.
 34. The method of claim 33, wherein thepolymerization reactor system comprises slurry polymerization reactors,loop slurry polymerization reactors, gas phase polymerization reactors,fluidized bed gas phase reactors, solution polymerization reactors,stirred tank reactors, or any combination thereof.
 35. The method ofclaim 33, wherein the high molecular weight component is produced in oneor more polymerization reactors and the low molecular weight componentis produced in one or more polymerization reactors, wherein the highmolecular weight component and the low molecular weight component areproduced in separate polymerization reactors.
 36. The method of claim33, wherein the composition comprises from about 45 to about 75 parts byweight high molecular weight component and from about 55 to about 25parts by weight low molecular weight component.
 37. The method of claim33, wherein the composition is characterized by a M_(w)/M_(n) less thanor equal to about 30, and a M_(z)/M_(w) less than or equal to about 10.38. The method of claim 33, wherein: the ethylene copolymer of the highmolecular weight component is produced using a Ziegler-Natta catalystsystem or a metallocene catalyst system; or the ethylene homopolymer ofthe low molecular weight component is produced using a Ziegler-Nattacatalyst system or a metallocene catalyst system; or both the ethylenecopolymer of the high molecular weight component and the ethylenehomopolymer of the low molecular weight component are produced using aZiegler-Natta catalyst system or a metallocene catalyst system.
 39. Themethod of claim 33, wherein the high molecular weight componentcomprises a copolymer of ethylene and a mono-1-olefin co-monomer havingfrom 3 to about 12 carbon atoms.
 40. The method of claim 33, wherein theethylene copolymer of the high molecular weight component is furthercharacterized by a M_(w) in a range from about 250 to about 1,000kg/mol, and a M_(z)/M_(w) less than or equal to about 2.5.
 41. Themethod of claim 33, wherein the ethylene homopolymer of the lowmolecular weight component is characterized by a M_(w) from about 30 toabout 50 kg/mol.
 42. A method of making a composition comprising a highmolecular weight component and a low molecular weight component, themethod comprising: (i) blending the high molecular weight component andthe low molecular weight component to form the composition; or (ii)producing the high molecular weight component and the low molecularweight component in a multiple polymerization reactor system comprisingat least two polymerization reactors configured in series or inparallel, and combining the high molecular weight component and the lowmolecular weight component in the reactor system to form thecomposition; or (iii) both (i) and (ii); wherein: a) the high molecularweight component comprises an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, a substantially constantshort-chain branching (SCB) profile across the molecular weightdistribution, and a number of short-chain branches (SCB) per 1000backbone carbon atoms from 5 to about 8; and b) the low molecular weightcomponent comprises an ethylene homopolymer or copolymer characterizedby a M_(w) from 25 to 60 kg/mol.
 43. The method of claim 42, wherein thepolymerization reactor system comprises slurry polymerization reactors,loop slurry polymerization reactors, gas phase polymerization reactors,fluidized bed gas phase reactors, solution polymerization reactors,stirred tank reactors, or any combination thereof.
 44. The method ofclaim 42, wherein the high molecular weight component is produced in oneor more polymerization reactors and the low molecular weight componentis produced in one or more polymerization reactors, wherein the highmolecular weight component and the low molecular weight component areproduced in separate polymerization reactors.
 45. The method of claim42, wherein the composition comprises from about 45 to about 75 parts byweight high molecular weight component and from about 55 to about 25parts by weight low molecular weight component.
 46. The method of claim42, wherein the composition is characterized by a M_(w)/M_(n) less thanor equal to about 30, and a M_(z)/M_(w) less than or equal to about 10.47. The method of claim 42, wherein: the ethylene copolymer of the highmolecular weight component is produced using a Ziegler-Natta catalystsystem or a metallocene catalyst system; or the ethylene homopolymer orcopolymer of the low molecular weight component is produced using aZiegler-Natta catalyst system or a metallocene catalyst system; or boththe ethylene copolymer of the high molecular weight component and theethylene homopolymer or copolymer of the low molecular weight componentare produced using a Ziegler-Natta catalyst system or a metallocenecatalyst system.
 48. The method of claim 42, wherein: the high molecularweight component comprises a copolymer of ethylene and a mono-1-olefinco-monomer having from 3 to about 12 carbon atoms; or the low molecularweight component comprises a copolymer of ethylene and a mono-1-olefinco-monomer having from 3 to about 12 carbon atoms; or both the highmolecular weight component and the low molecular weight componentcomprise a copolymer of ethylene and a mono-1-olefin co-monomer havingfrom 3 to about 12 carbon atoms.
 49. The method of claim 42, wherein theethylene copolymer of the high molecular weight component is furthercharacterized by a M_(w) in a range from about 250 to about 1,000kg/mol, and a M_(z)/M_(w) less than or equal to about 2.5.
 50. Themethod of claim 42, wherein the ethylene homopolymer or copolymer of thelow molecular weight component is characterized by a M_(w) from about 30to about 50 kg/mol.
 51. A method of making a composition comprising ahigh molecular weight component and a low molecular weight component,the method comprising: (i) blending the high molecular weight componentand the low molecular weight component to form the composition; or (ii)producing the high molecular weight component and the low molecularweight component in a multiple polymerization reactor system comprisingat least two polymerization reactors configured in series or inparallel, and combining the high molecular weight component and the lowmolecular weight component in the reactor system to form thecomposition; or (iii) both (i) and (ii); wherein: a) the high molecularweight component comprises an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, a substantially constantshort-chain branching (SCB) profile across the molecular weightdistribution, and a number of short-chain branches (SCB) per 1000backbone carbon atoms from about 4 to about 8; and b) the low molecularweight component comprises an ethylene homopolymer or copolymercharacterized by a M_(w) from 25 to 60 kg/mol and a M_(w)/M_(n) greaterthan or equal to
 5. 52. The method of claim 51, wherein thepolymerization reactor system comprises slurry polymerization reactors,loop slurry polymerization reactors, gas phase polymerization reactors,fluidized bed gas phase reactors, solution polymerization reactors,stirred tank reactors, or any combination thereof.
 53. The method ofclaim 51, wherein the high molecular weight component is produced in oneor more polymerization reactors and the low molecular weight componentis produced in one or more polymerization reactors, wherein the highmolecular weight component and the low molecular weight component areproduced in separate polymerization reactors.
 54. The method of claim51, wherein the composition comprises from about 45 to about 75 parts byweight high molecular weight component and from about 55 to about 25parts by weight low molecular weight component.
 55. The method of claim51, wherein the composition is characterized by a M_(w)/M_(z) less thanor equal to about 30, and a M_(z)/M_(w) less than or equal to about 10.56. The method of claim 51, wherein: the ethylene copolymer of the highmolecular weight component is produced using a Ziegler-Natta catalystsystem or a metallocene catalyst system; or the ethylene homopolymer orcopolymer of the low molecular weight component is produced using aZiegler-Natta catalyst system or a metallocene catalyst system; or boththe ethylene copolymer of the high molecular weight component and theethylene homopolymer or copolymer of the low molecular weight componentare produced using a Ziegler-Natta catalyst system or a metallocenecatalyst system.
 57. The method of claim 51, wherein: the high molecularweight component comprises a copolymer of ethylene and a mono-1-olefinco-monomer having from 3 to about 12 carbon atoms; or the low molecularweight component comprises a copolymer of ethylene and a mono-1-olefinco-monomer having from 3 to about 12 carbon atoms; or both the highmolecular weight component and the low molecular weight componentcomprise a copolymer of ethylene and a mono-1-olefin co-monomer havingfrom 3 to about 12 carbon atoms.
 58. The method of claim 51, wherein theethylene copolymer of the high molecular weight component is furthercharacterized by a M_(w) in a range from about 250 to about 1,000kg/mol, and a M_(z)/M_(w) less than or equal to about 2.5.
 59. Themethod of claim 51, wherein the ethylene homopolymer or copolymer of thelow molecular weight component is characterized by a M_(w) from about 30to about 50 kg/mol.
 60. A method of making a composition comprising ahigh molecular weight component and a low molecular weight component,the method comprising: (i) blending the high molecular weight componentand the low molecular weight component to form the composition; or (ii)producing the high molecular weight component and the low molecularweight component in a multiple polymerization reactor system comprisingat least two polymerization reactors configured in series or inparallel, and combining the high molecular weight component and the lowmolecular weight component in the reactor system to form thecomposition; or (iii) both (i) and (ii); wherein: a) the high molecularweight component comprises an ethylene copolymer characterized by aM_(w)/M_(n) less than or equal to about 3.5, a substantially constantshort-chain branching (SCB) profile across the molecular weightdistribution, and a number of short-chain branches (SCB) per 1000backbone carbon atoms from about 4 to about 8; and b) the low molecularweight component comprises an ethylene homopolymer or copolymercharacterized by a M_(w) from 25 to 60 kg/mol, and substantially zeroshort-chain branches (SCB) per 1000 backbone carbon atoms.
 61. Themethod of claim 60, wherein the polymerization reactor system comprisesslurry polymerization reactors, loop slurry polymerization reactors, gasphase polymerization reactors, fluidized bed gas phase reactors,solution polymerization reactors, stirred tank reactors, or anycombination thereof.
 62. The method of claim 60, wherein the highmolecular weight component is produced in one or more polymerizationreactors and the low molecular weight component is produced in one ormore polymerization reactors, wherein the high molecular weightcomponent and the low molecular weight component are produced inseparate polymerization reactors.
 63. The method of claim 60, whereinthe composition comprises from about 45 to about 75 parts by weight highmolecular weight component and from about 55 to about 25 parts by weightlow molecular weight component.
 64. The method of claim 60, wherein thecomposition is characterized by a M_(w)/M_(n) less than or equal toabout 30, and a M_(z)/M_(n) less than or equal to about
 10. 65. Themethod of claim 60, wherein: the ethylene copolymer of the highmolecular weight component is produced using a Ziegler-Natta catalystsystem or a metallocene catalyst system; or the ethylene homopolymer orcopolymer of the low molecular weight component is produced using aZiegler-Natta catalyst system or a metallocene catalyst system; or boththe ethylene copolymer of the high molecular weight component and theethylene homopolymer or copolymer of the low molecular weight componentare produced using a Ziegler-Natta catalyst system or a metallocenecatalyst system.
 66. The method of claim 60, wherein: the high molecularweight component comprises a copolymer of ethylene and a mono-1-olefinco-monomer having from 3 to about 12 carbon atoms; or the low molecularweight component comprises a copolymer of ethylene and a mono-1-olefinco-monomer having from 3 to about 12 carbon atoms; or both the highmolecular weight component and the low molecular weight componentcomprise a copolymer of ethylene and a mono-1-olefin co-monomer havingfrom 3 to about 12 carbon atoms.
 67. The method of claim 60, wherein theethylene copolymer of the high molecular weight component is furthercharacterized by a M_(w) in a range from about 250 to about 1,000kg/mol, and a M_(z)/M_(w) less than or equal to about 2.5.
 68. Themethod of claim 60, wherein the ethylene homopolymer or copolymer of thelow molecular weight component is characterized by a M_(w) from about 30to about 50 kg/mol.